Note: Descriptions are shown in the official language in which they were submitted.
CA 02525234 2005-11-08
- 1 -
Container, Storing Bath and a Method of Producing the
Container
FIELD OF THE INVENTION
[0001]
This invention is related, for example, to a container
suitable for transporting molten aluminum, a bath used for
the container and a method of producing the container.
BACKGROUND OF THE INVENTION
[0002]
In a factory where aluminum is molded using many
die-casting machines, an aluminum materialisoftensupplied
not only from within the factory but also from outside of
the factory. In such a case, a container storing aluminum
in a melt is carried from a factory on the material supply
side to a factory on the molding side to supply to each
of the die-casting machines the material kept in the melt.
(For example, see the patent literature 1)
[0003]
A container of this kind is produced, for example,
by coating a plurality of layers such as a heat-insulating
layer or a refractory layer onto an inner wall of the frame
made of metal.
[Patent Literature]JP-UM-A-3-31063 (Fig. 1)
DISCLOSURE OF THE INVENTION
PROBLEMS TO BE SOLVED
[0004]
CA 02525234 2005-11-08
- 2 -
However, as described in the patent literature 1,
in a hermetically closed-type container that supplies the
molten metal to an outside using a pressure difference,
a fluid component contained in the lining and a component
of the lining crystallized as an aqueous solution evaporated
by the heat of the molten metal inside container, causing
the pressure inside the container to rise to an unexpected
level. In such a case, for example, the molten metal may
gushes out unexpectedly from a pipe provided to become a
flow path for providing the molten metal to the outside.
In order to prevent such case, it is necessary to dry the
lining thoroughly after the step of molding thereof, however,
being comprised of a plurality of layers, the drying step
is very troublesome. For this reason, there is a problem
that the production of the container requires very long
time, thus the productivity thereof is very low.
[0005]
In addition, in a hermetically closed container of
this type, it is necessary to avoid cracking of the lining
as much as possible in order to prevent the loss of pressure
and gas being mixed into the container. For example, when
the cracking reaches from a space inside the container to
the flow path, a gas for applying pressure directly flows
through the cracking portion into the flow path, and the
supply of the molten metal becomes unstable. Furthermore,
there is also a problem in that the molten metal in a state
of containing the gas therein is blown out of the pipe and
CA 02525234 2005-11-08
- 3 -
molten metal with high temperature is splattered in a
surrounding area. However, such cracking in the lining
is inevitably caused by mechanical vibration given to the
container when being transported, a thermal expansion of
the molten metal etc. In such case, replacing the lining
(relining) is normally performed. However, there is a
problem in that such relining being very inefficient since
a plurality of layers must be coated and dried.
[0006]
The present invention is made to overcome such problem,
and the object of this invention is to provide a container
that is capable of preventing unexpected rise of the pressure
inside the container caused by the problem pertaining to
the lining.
[0007]
In addition, object of the present invention is to
provide a container in which re-lining process can be carried
out effectively or the method of producing thereof.
MEANS FOR SOLVING THE PROBLEM
[0008]
To solve such problem, the prime object of the present
invention is to provide a container capable of being
hermetically closed and storing a molten metal and supplying
the molten metal to an outside using a pressure difference
comprised of a frame body having an opening at an upper
portion thereof, an heat-insulating wall laid onto an inner
wall of the frame body, a refractory storing bath, detachably
.. CA 02525234 2005-11-08
- 4 -
inserted to an inner side of the heat-insulating wall from
the opening of the frame body to be integrally provided
with the frame body, a lid that covers the opening of the
frame body, an introductory (or induction)portion that
introduces (or induces) a gas for applying pressure into
the storing bath covered with the lid and a supplying portion
that supplies the molten metal stored inside the storing
bath to an outside.
[0009]
Since a container of the present invention has a
structure such that the heat-insulating wall is being laid
onto the inner side of the frame body and the refractory
storing bath is detachably inserted from the opening of
the frame body to be integrally provided with the container,
a member that comprises the container can be made into
components. Thus manufacturing of the container can be
substantially made into "assembling" of such components.
In other words, a process such as casting of lining that
could be regarded as a step of producing a masterpiece can
be removed. Especially, process of casting a lining
requires considerable long time and also an individual
product tend to become different from each other. The
present invention can provide a container of high quality
efficiently. For this reason, maintenance of a component,
for example, a lining (that corresponds to a heat-insulating
wall or a refractory storing bath) can be performed
individually, therefore, problem that the inner pressure
CA 02525234 2005-11-08
- 5 -
rising unexpectedly caused by the defects pertaining to
lining can be prevented. In addition, relining process can
be carried out asmerely replacing the component. Therefore,
relining can be performed efficiently. Such effect is just
an example, and merit that of making the lining into a
component will have an effect to other fields.
[0010]
Here, in the present invention, it is preferable that
an insulating member in granule or powder form is provided
between the heat-insulating walland the refractorystoring
bath.
The insulating member of either a granule form or
a powder form eases the mechanical impacts inflicted to
the refractory storing bath, thus the cracking can be
prevented from occurring. In addition, use of this member
facilitatesreplacement operation of the refractorystoring
bath. Therefore, relining can be performed easily and
efficiently.
[0011]
It is preferable for the present invention that a
refractory and heat-insulating member containing a binder
having a fusing point higher than that of the molten metal
is inserted between the heat-insulating wall and the
refractorystoringbath. For example, when the molten metal
is a molten aluminum and melts at 720 degrees Celsius, a
binder that melts at 800 degrees Celsius can be used. In
this case, as a refractory and heat-insulating member, for
CA 02525234 2005-11-08
- 6 -
example, a material containing alumina for 35 percent by
weight and silica for 25 percent by weight can be used.
A solid refractory insulating member as explained
above can be formed by inserting a powder form refractory
and insulating member between the heat-insulating wall and
the refractory storing bath when assembling, then having
it melt by heating thereof at 800 degrees Celsius then having
it solidify later. Using the refractory insulating member
in a solid form prevents sliding in a position of the storing
bath when transporting, and the like, the container. In
addition, since nothing in fluid form is usedwhen assembling
the container, drying step is not necessary to be included.
Furthermore, the breaking up of the storing bath at the
time of replacement thereof may be facilitated by using
a member more fragile than the storing bath as the refractory
insulating member in solid form.
[0012]
It is preferable that the storing bath has a flow
path for flowing the molten metal between the storing bath
and an outside located inside the storing bath to be
integrally provided therewith. In other words, it is
preferable that the storing bath has a flow path that consists
a part of the supplying portion in the inside thereof . In
such a case, the supplying portion is preferably comprised
of the flow path and a pipe connected to the flow path.
[0013]
Another embodiment ofthe presentinvention regarding
CA 02525234 2005-11-08
a method of producing a container capable of being
hermetically closed storing a molten metal and supplying
the molten metal to an outside using a pressure difference
that comprises, laying an heat-insulating wall on an inner
wall of the frame body having an opening at an upper portion
thereof, inserting a refractory storing bath from the
opening of the container to an inner side of the
heat-insulating wall and covering the opening of the frame
body with the lid.
According to the present invention, since the storing
bath is detachably inserted from the opening of the frame
body to the inner side of the heat-insulating wall, the
production of the container and the lining can be processed
very easily. In addition, a dried heat-insulating wall and
a refractory storing bath, both being made into components,
can be used, drying step becomes unnecessary thus time
consumed for manufacturing the container can be very short.
[0014]
It is preferable that the method further comprises
the steps of inserting between the heat-insulating wall
and the refractory storing bath, (1) a refractory and
heat-insulating member in granule form, (2) refractory and
heat-insulating member in powder form or (3) a refractory
and heat-insulating member containing a binder having a
fusing point higher than that of the molten metal and causing
the refractory insulating member to melt and solidifies.
[0015]
CA 02525234 2005-11-08
g
Another embodiment of the present invention is
comprised of a storing bath for storing a molten metal used
for a container capable of storing a molten metal and
supplying the molten metal to an outside using a pressure
difference, having approximately a tubular shape, and a
protruding portion extending to a vertical direction formed
on an inner side of the container and the flow path for
the molten metal is provided inside the protruding portion.
[0016]
Another embodiment of the present invention is
comprised of a storing bath for storing a molten metal used
for a container capable of storing a molten metal and
supplying the molten metal to an outside using a pressure
difference, having approximately a cylindrical shape, and
a protruding portion extending to a vertical direction
formed on an inner side of the container, the flow path
for the molten metal has at least a pre-cast segment provided
in the protruding portion, and a pipe made of ceramics
surrounding at least a part of the flow path. The pipe
made of ceramics may be fixed integrally to the pre-cast
segment or may be provided as being exchangeable. In the
latter case, when the pipe is fixed using a cushion member
having strength smaller than the pre-cast segment and the
pipe made of ceramics, the ceramics pipe can be replaced
like a cartridge type. In addition, the ceramics pipe has
a concave and convex portion on the outer surface in order
to prevent the sliding of the pipe and the storing bath.
CA 02525234 2005-11-08
- 9 -
The concave and convex portion may be something like a brim
or may be a groove on either side. With such concave and
convex portion, the pipe can be inhibited from sliding or
falling apart.
[0017]
Furthermore, it is preferable to have an overhang
on an upper portion of the protruding portion on an inner
side of the storing bath. The overhang portion provides
sufficient size of plane for connecting the storing bath
to the container body and then to the lid.
[0018]
The storing bath of the present invention is for
storing amoltenmetal used for a container capable of storing
a molten metal and supplying the molten metal to an outside
using a pressure difference and comprised of engaging
members fixed to an upper face, outer surface or an inner
surface thereof enabling the connection with an outside.
[0019]
Another embodiment of the present invention is a
container capable of storing a molten metal comprised of
a frame, a storing bath (pre-cast segment) having a flow
path for causing the molten metal flow from the inside to
the outside of the container and a pipe disposed to surround
at least a part of the flow path.
[0020]
Yet another aspect of the present invention is a
container capable of storing a molten metal comprises a
CA 02525234 2005-11-08
- 10 -
frame and a storing bath, having a flow path for flowing
the molten metal therein; the flow path being provided an
inside of the frame and at least a part thereof is surrounded
by a member restricting a flow of a gas. A molded product
made of ceramics material and the like can be cited as a
storing bath of this type . Here, ceramics means a non-metal
inorganic materialproduced by taking processingsteps such
as sintering and molding, containing at least one of, for
example, A1203, Si02, SiC, SiN, Si3N4, TiN, Ti02, carbon and
graphite as a primary component. In addition, a molded
product ofso-calledindeterminateform refractory material
or sintered products is included in the ceramics defined
as above . As a storing bath, material having a big strength,
aluminum proof (with regard to permeation and reactivity)
and spalling proof are preferable.
[0021]
In addition, as a restricting member of this kind,
materials such as metals (including an alloy) and ceramics
can be cited. Here, ceramics means a non-metal inorganic
material produced by taking processing steps such as
sintering and molding, containing at least one of, for
example, A1203, Si02, SiC, SiN, Si3N4, TiN, Ti02, carbon and
graphite as a primary component . Further, a molded product
of so-called indeterminate form refractory material or
sintered products are included in the ceramics defined as
for the storing bath.
[0022]
CA 02525234 2005-11-08
- 11 -
Furthermore, the restricting member is preferably
constituted of a layer thermodynamically uniform from a
macroscopic viewpoint. This is because in the case of a
mixture being made of a plurality of materials different
in the physical properties, in other words, in the case
of a mixture being made of a layer thermodynamically
non-uniform from a macroscopic viewpoint, cracking and the
like are likely to occur caused by periodically applied
thermal load, difference in the thermal expansion
coefficients and so on, and thereby a gas is allowed to
flow in. According to the present invention, because of
the pipe made of restricting member, gas can be inhibited
from entering into the flow path, even when the flow path
of the storing bath cracks.
[0023]
In the present invention, as the pipe, a ceramics
pipe or ametal pipe inside of which is linedwith a refractory
material is preferably used. As the metal, for instance,
SGP, STPT (carbon steel tube for high temperature pipe)
or STPG (carbon steel tube for pressure pipe) can be used.
[0024]
As the refractory member, for instance, refractory
members (including refractory caster, heat-insulating
material, and heat-insulating caster) for molten aluminum,
molten magnesium and so on can be used. . These refractory
members may be mixed with ceramics, carbon or graphite.
Thereby, the non-wettability of the molten metal to the
CA 02525234 2005-11-08
- 12 -
pipe can be improved and the strength thereof can also be
improved. Furthermore, the maintenance also becomes
easier. More specifically, as the refractory members,
trade name TMU 85AEFN (A1203: 82 percent, Si02: 13 percent)
and SC SAE85 (A1203: 8 percent, SiC: 83 percent, Si02: 7
percent) both manufactured by NIPPON TOKUSHUROZAI KK can
be cited. However, the present invention is not restricted
to such materials but ceramics as described above can be
used.
[0025]
In the present invention, since the flow path is
provided inside the storing bath, the thermal conduction
from the molten metal storing portion to the flow path is
high. Accordingly, since the heat retaining property of
the molten metal that flows the flow path can be improved
and the fluidity can be maintained, the possibility that
the flow path being clogged becomes extremely low. In
addition, since the flow path is surrounded with a member
that restricts the flow of a gas such as a metallic pipe
or a ceramics pipe, a gas for applying pressure does not
leak to the flow path. Accordingly, the molten metal can
be stably supplied. Furthermore, the ceramics layer is
effective for the thermal insulation of the flow path since
the ceramics layer has high thermal conductivity. Here,
ceramics means a material containing at least one of, for
example, A1203, SiOz, SiC, SiN, Si3N4, TiN, TiOz, carbon and
graphite as a primary component. In addition, a molded
CA 02525234 2005-11-08
- 13 -
product ofso-calledindeterminateform refractory material
or sintered products is included in the ceramics defined
as above. For example, as a storing bath, trade name
LEOCAST-15M, trade name LEOCAST-32T, trade name AC-NL-1
of TYK corp. , can be cited. For example, as the ceramic pipe,
trade name SCN (SiC :74.8 percent, Si3N9: 23.54 percent)
manufactured by TYK Corp., trade name KN-101 (mainly made
of Si3Nq) manufactured by Kubota Corp., trade name SN 220
(mainly made of Si3N4) manufactured by Kyocera Corporation,
and trade name Sialon HCN 10 (mainly made of S13N4)
manufactured by Hitachi Metals Ltd. can be cited. These
are molded by means of, for instance, a CIP (Cold Isostatic
Press ) method. Pressure applied for such case is preferably
10000 kgf/cm2 or more. In general, the ceramics pipe has
high degree of mechanical strength but cracking is likely
to occur owing to the thermal load. However, in the present
invention, since the ceramic pipe is buried in the storing
bath, the outside of the pipe is not directly exposed to
a high temperature during preheating of the container,
therefore, thelifetime thereof isverylong. Furthermore,
even when the pipe cracks caused by a vibration at a time
of transportation, the supply of the molten metal can be
continued as far as the fl ow path is maintained. Accordingly,
a situation where the molten metal becomes suddenly
incapable of being supplied at the user side and the container
has to be carried back can be avoided.
[0026]
CA 02525234 2005-11-08
- 14 -
Here, from the viewpoint of the heat-retaining
property of the flow path, the flow path preferably is
disposed inside the lining from a position close to a bottom
portion inside the container to a top surface side of the
container. As an example of arrangement of the flow path,
a storing bath having a protruding portion being formed
such that to extend to an upper direction and to a lower
direction and to protrude to an inner wall side of the
container, and a f low path being formed inside the protruding
portion along with the direction that the protruding portion
extends. A container for supplying molten metal can be
assembled by disposing such storing bath inside the frame
and refractory and heat-insulating member between the
storing bath and the frame.
[0027]
Furthermore, when the flow path is structured so that
being surrounded by a pipe buried in the lining, and when
the pipe is made into a cartridge, the flow path becomes
exchangeable once it is clogged. The pipe may be disposed
so as to surround not the whole of the flow path but a part
thereof. When the storing bath itself is made of a fine
ceramics, basically there is no need to provide a pipe,
however, production cost would rise.
[0028]
When a structure where an inner surface of the pipe
is covered with a member having refractory property, the
durability of the pipe can be improved and the gas for applying
CA 02525234 2005-11-08
- 15 -
pressure can be prevented from leaking into the flow path
for a long time period. Furthermore, the protruding portion
preferably has a tapered shape in the neighborhood of a
lower opening of the pipe so that the inside of the container
may become wider. Thereby, during the maintenance of the
container, the accessibility from the inside of the
container toward the lower portion of the pipe can be improved.
This configuration, together with a detachable structure
of the lid, improves the maintenance properties of the
container and the reliability of the container.
[0029]
Furthermore, structure of a storing bath having a
flow path therein is explained here, however, the storing
bath is not limited to this form. For example, a storing
bath with a simple cylindrical shape may be adopted and
the flow path of the molten metal can be structured solely
with a pipe made of ceramics.
[0030]
The container body of the present invention basically
adopts prefabricated frame structure of molded products.
For example, the container body of the present invention
is~structured such that disposing a refractory and
heat-insulating material between a pre-cast segment of the
storing bath that is molded before the assembly, and a frame
made of metal . The frame and the storing bath were prepared
beforehand. A refractory material (for example, a molded
product such as U-brid (TM), microtherm(TM)) is laid on
CA 02525234 2005-11-08
- 16 -
the inner side of the frame, and a dried powder of
indeterminate form refractory material is laid on the bottom
thereof and the storing bath is placed thereon. Then the
container body of the present invention is structured as
filling the gap between the insulating material and the
storing bath with a dried powder of indeterminate form
refractory material. For a container of the present
invention, it is preferable to mix a thermosetting type
binder material with the dried powder form of indeterminate
form refractory material that surrounds the bottom and
outside of the storing bath. With this configuration, the
binder solidifies by the heat from pre-heating of the
container when being used for the first time. As a result,
the strength of the indeterminate form refractory material
increases which leads to an improved "ability to hold" of
the storing bath. In addition, the storing bath will be
held firmly even when being tilted at the time of maintenance,
turned upside down, applied with vibration at the time of
transportation thus breaking down caused by unexpected
stress and sliding from its original position can be
prevented.
BEST MODE FOR CARRYING OUT THE INVENTION
[0031]
Hereinafter, embodiments of the present invention
will be described with reference to the drawings.
[0032]
FIG 1 is an exploded viewof the container in connection
CA 02525234 2005-11-08
- 17 -
with an embodiment of the present invention, FIG 2 is a
sectional view of the container in assembly, FIG 3 is a
front view thereof, FIG 4 is a plane view without a lid
and FIG 5 is a plane view with a lid.
A container 1 is comprised of a container body 2,
a lid 3 and a first pipe 4 and a second pipe 5.
[0033]
The container body 2 has a frame body 6 made of metal
bottomed and approximately cylindrically shaped having an
opening at a top thereof, a heat-insulating wall 8 laid
on an inner wall 7 of the frame body 6 having an elasticity,
and a refractory storing bath 9 detachably disposed on the
inner wall 7 side of the heat-insulating wall from the opening
of the frame body 6.
[0034]
A refractory and heat-insulating member 10 in granule
form or powder form is inserted in a space between the
heat-insulating wall 8 and the storing bath 9. As such
refractory and heat-insulating member 10, for example, a
dried powder of the heat-insulating material containing
Si02, A1203 and the like can be used. In addition, as another
embodiment, for example, 35 percent by weight of Alumina,
percent by weight of Silica and a solid form of refractory
and heat-insulating member containing a binder having a
25 fusing point of 800 degrees Celsius may be used as the
refractory and heat-insulating member 10. In this case,
the refractory and heat-insulating member 10 in powder form
CA 02525234 2005-11-08
- 18 -
is fed into a space between the heat-insulating wall 8 and
the storing bath 9 then the binder is heated to a temperature
above 800 degrees Celsius, and let it solidify later.
Furthermore, using a member more fragile than that of the
storing bath 9 as a refractory and heat-insulating member
in solid form enables to break up the storing bath 9
easily at a time of replacement of the storing bath 9.
Therefore, the replacement operation of the storing bath
9 becomes easy.
10 [0035]
A flange 11 is provided at an outer peripheral of
the opening of the frame body 6. A pair of a channel member
12 is attached to the bottom, outside of the frame body
6. A fork (not shown) of a fork lift truck for transporting
the container 1 is disposed so that it is capable of being
inserted and being pulled out.
[0036]
A molded product such as a U-brid (TM),
microtherm (TM) and the like can be used as a heat-insulating
wall 8. The heat-insulating wall 8 is, for example,
structured from a plurality of pieces of fragments being
laid on the inner wall 7 of the frame body 6 with an adhesive
agent.
[0037]
A pair of protruding portion 13 is disposed integrally
with the storing bath 9 in a vertical direction on the inner
circumference of the inner wall of the storing bath 9. A
CA 02525234 2005-11-08
- 19 -
flow path 14 for having a molten metal flow between inside
and outside container is provided inside the protruding
portion 13 along with the vertical direction. The flow path
14 penetrates from a position close to the bottom of the
inside of the storing bath 9 to upper surface.
[0038]
Here, the protruding portion 13 has a overhang
structure close to an upper surface portion of the storing
bath forming a structure 13a. With this structure, the
air-tightness between the upper surface of the protruding
portion 13 and the lid 3 is secured, thus the molten metal
is prohibited from leaking out therefrom.
[0039]
A first pipe 4 made of, for example, ceramics is
integrally fixed to the flow path 14. With this
configuration, intrusion of a gas into the flow path 14
at a time of pressurization of the storing portion can be
prevented. The first pipe 4 is disposed so that it protrudes
slightly from the upper surface of the storing bath 9. In
order to protect the protruding parts of the first pipe
4, a protective layer 17 may be protruded to integrally
surround the first pipe 4. This protective layer 17 may
be omitted. In addition, the shifting in position of the
first pipe 4 can be prevented by providing a plurality of
grooves in a horizontal direction with 3 mm in depth and
50mm in length on the surface of the first pipe 4 . Meanwhile,
the first pipe inserted may be provided replaceable.
CA 02525234 2005-11-08
- 20 -
[0040]
In addition, the flow path 14 is extended to a the
main body (on the side) of the storing bath 9 beyond the
protruding portion 13 and an opening 15 that opens up to
the inner side of the container connected to the flow path
14 is provided at around the bottom of the container.
However, at this part, the passage that extends as far as
the to the storing bath 9 does not exist and in consequence
a stage portion 16 protruding from the main body of the
storing bath 9 is provided. In order to maintain the space
between the lower end surface of the first pipe 4 and the
bottom face of the storing bath 9, (corresponds to, for
example a height of the opening 15) , the stage portion 16
constitutes a holding member holding the lower end surface
of the pipe 4. With this configuration, the first pipe 4
can be prevented from being fallen off.
[0041]
A corner portion 18 where the bottom face and the
inner wall crosses is set to in a range of approximately
R50mm to R80mm. Thereby the cracking of the storing bath
9 can be prevented. In addition, four holds 19 for attaching
anchor bolts as engaging member are disposed at
predetermined positions on the upper surface of the storing
bath 9. With this configuration, the lifting and lowering
movement of the storing bath 9 through anchor bolts using
a crane becomes possible, leading to improvement of the
workability in the manufacturing process. Further,
CA 02525234 2005-11-08
- 21 -
replacing the storing bath 9 is easy using such engaging
member.
[0042]
A lid 3 is comprised of a large lid 20 and a hatch
(a small lid) 21. A flange 22 is disposed at an outer
periphery of the large lid 20 and the container body 2 and
the lid 3 is fixed together as securing the flange 22 and
a flange 11 provided at a periphery of the opening of the
frame body 6 with a bolt (not shown) and the container 1
becomes hermetically closed.
[0043]
At almost the center of the aforementioned large lid
20, an opening 23 is provided, and a hatch (little lid)
21 with a handle (not shown) attached thereto is disposed
at the opening 23. The hatch 21 is provided at a position
slightly higher than the upper face of the large lid 20.
A portion on the outer periphery of the hatch 21 is attached
to the large lid 20 through a hinge 25. This allows the
hatch 21 to freely open and close against the opening 23
of the large lid 20. In addition, bolts with handles 26
for fixing the hatch 21 to the large lid 20 are attached
at two points of the outer periphery of the hatch 21 in
a position opposite to the position to which the hinge 21
is attached. The hatch 21 is fixed to the large lid 20 by
closing the opening 23 in the large lid 20 with the hatch
21 and rotating the bolts 26 with handle . On the other hand,
by inversely rotating the bolt 26 with the handle to release
CA 02525234 2005-11-08
- 22 -
the fixation, the hatch 21 can be opened from the opening
23 of the large lid 20 . Then, with the hatch 21 being opened,
maintenance of the inside of the container 1 and insertion
of a gas burner at the time of preheating can be performed
through the opening 23.
[0044]
Further, a passage 27 for internal pressure control
for reducing and applying pressure in the container 1 is
provided at a center or a position slightly off from the
center of the hatch 21 . To the passage 27, a pipe for applying
and reducing pressure (not shown) is to be connected. The
pipe extends upward from the passage 27, bends at a
predetermined height, and extends in the horizontal
direction. The surface of a portion of the pipe that is
to be inserted into the passage 27 is threaded, and on the
other hand, the passage 27 is also threaded. This firmly
screws the pipe to the passage 27. FIG. 5 shows a state
where the passage 27 is closed by the cap 28. The other
passage 29, (there are many in practice), is also closed
by the cap 30, however, for example, an electrode for
detecting, for example, a liquid surface is to be inserted
into the passage 29. In addition, the large lid 20 and the
hatch 21 is structured as such that a lining (layers of
a heat-insulating layer and a refractory layer) is disposed
on an inner side of the frame made of metal. Here, the cap
28 and the cap 30 are socket (a hidingmember) that constitutes
a coupler of a plug and a socket.
CA 02525234 2005-11-08
- 23 -
[0045]
An opening 31 is provided at a position corresponding
to the flow path 14 of the large lid 20 . The outer periphery
thereof is protruded and a flange 32 is provided at the
top of the protruded portion. The flange 32 is fixed with
the flange 33 disposed at the second pipe 5 and the second
pipe 5 is fixed to the container 1.
[0046]
According to container 1 of the present invention,
when inside the container 1 is applied with pressure through
the passage 27, the molten aluminum stored in the storing
bath 9 is supplied to an outside through the flow path 14
and the pipe 5 . In addition, when inside the pressure inside
the container 1 is reduced through the passage 27, the molten
aluminum is introduced into the container 1 from an outside
through the flow path 14 and the pipe 5 and the molten aluminum
is stored in the storage tank 9.
[0047]
Since the container 1 of the present invention has
a structure such that the heat-insulating wall 8 is being
laid onto the inner side of the container body 6 and the
refractory storing bath 9 is detachably inserted from the
opening 5 of the frame body 6 to be integrally provided
with the container, the time consumed for drying can be
shortened and the lining inside the container 1 can be
prevented from containing fluid. Especially, a
heat-insulating wall 8 and a refractory storing bath 9 are
CA 02525234 2005-11-08
- 24 -
both being made into dried components, drying step becomes
unnecessary thus time consumed for manufacturing the
container can be very short.
[0048]
Next, description will be made on the method of
manufacturing the container 1 with referenced to FIG 1.
(1) Laying the heat-insulating wall 8 on an inner wall 7
of the frame body 6. The heat-insulating wall 8 is, for
example, formed as a plurality of pieces of fragments being
laid onto the inner wall 7 of the frame body 6 with an adhesive
agent.
(2) Furthermore, a block of, for example, 50mm X 50mm in
area and 25mm of thickness may be laid on the four places
on the inner bottom face of the frame body 6 laid with the
heat-insulating wall 8. This block is for keeping the
horizontal level of the storing bath 9 to be inserted by
holding the outer bottom face thereof.
(3) Spreading a heat-insulating member 10 either in granule
form or powder form (or dried powder of the heat-insulating
member) to the inner bottom face of the frame body 6 laid
with the heat-insulating wall 8.
(4) Inserting the storing bath 9 to the inner wall side
of the heat-insulating wall 8 from the opening of the frame
body 6. At this time, a plate for determining the position
is disposed at a hold 19 for attaching an anchor bolt of
the storing bath 9 and a protective layer 17, and, for example,
the position is fixed by having the storing bath 9 match
CA 02525234 2005-11-08
- 25 -
with the bolt hole provided on the flange of the frame body
6. In other words, the position adjustment of the frame
body 6 and the storing bath 9 is performed based on the
above-mentioned bolt-hole.
(5) A refractory and heat-insulating member 10'in either
granule form or powder form is poured into the space formed
between the heat-insulating wall 8 and the storing bath
9 and the space is filled with the refractory and
heat-insulatingmember 10 by, for example, having it vibrate.
Furthermore,thelayer of the refractory and heat-insulating
member 10 can be solidified caused by the heat obtained
when using the container 1 (heat from the molten aluminum
or heat of gas burner at a time of pre-heating) by mixing
a binder in the refractory and heat-insulating member 10.
Here, 10 per cent by weight of a thermosetting type binder
is mixed herewith.
(6) A flange is fixed with the bolt as the lid 3 is placed
on the opening and having packing in between. It is
preferable that the lid 3 to be dried beforehand.
(7) The first pipe 4 is inserted into the flow path 14 of
the storing bath 9 through the opening 31 of the large lid
20. In addition, the first pipe 4 may be fixed integrally
with the storing bath 9 as a molded product of a pre-cast
segment.
(8) The second pipe 5 is fixed with the flange 33 disposed
at the second pipe 5 and the second pipe 5 is fixed to the
container 1.
CA 02525234 2005-11-08
- 26 -
[0049]
As explained above, according to the method of
manufacturing the container 1 of this embodiment, since
the storing bath 9 is detach ably inserted from the opening
of the frame body 6 to the inner side of the insulating
wall, the production of the container 1 can be done very
easily. In addition, a dried heat-insulating wall 8 and
a refractory storing bath 9 and the like can be used when
assembling the container, drying step becomes unnecessary
thus time consumed for manufacturing the container can be
very short.
[0050]
Next, another embodiment of the method of
manufacturing the container 1 will be described.
(1) Laying the heat-insulating wall 8 on an inner wall 7
of the frame body 6.
(2) As shown in FIG 6, a position locating tool having a
diameter larger than that of the upper opening and having,
for example, a semi circle in shape, is to be placed on
top of the upper opening. With regard to two out of the
four holes 19 for attaching anchor bolts, anchor bolt 43
is fixed through the hole 42 provided on the
position-locating tool for locating position. For the
remaining two holes 19 for attaching the anchor bolt, the
anchor bolt 43 can be attached directly.
(3) The storage tank 9 is hanged up as hooks 44 of the crane
catches the anchor bolts 43 attached at four positions and
CA 02525234 2005-11-08
- 27 -
the storage tank 9 is being held into the frame body 6 laid
with the insulating wall 8.
(4) As shown in FIG 7, for example, four holes 45 (refer
to FIG 6) provided on the position locating tool for locating
positions and the bolt hole 46 provided on the outer periphery
of the frame body 6 and the flange 11 (i.e. holes provided
for fixing the large lid 20 and the flange 22 with the bolt)
are adjusted to match with each other in position, and the
hole 45 (refer to FIG 6) and the hole 46 are fixed with
the bolt 47. In this way, the position of the storing bath
9 is determined.
(5) A refractory and heat-insulating member 10 in powder
form containing a binder is poured into a space formed between
the heat-insulating wall 8 and the storing bath 9 and the
refractory and heat-insulating member 10 is temporarily
melted by heating thereof at approximately 800 degrees
Celsius and have it solidified. This step can be performed
without the position-locating tool for locating position
or with the position-locating tool being attached.
(6) A flange 6 is fixed with the bolt as the lid 3 is placed
on the opening and having packing in between. It is
preferable that the lid 3 to be dried beforehand.
(7) The first pipe 4 is inserted into the flow path 14 of
the storing bath 9 through the opening 31 of the large lid
20. In addition, the first pipe 4 may be fixed integrally
with the storing bath 9 as a molded product of a pre-cast
segment.
CA 02525234 2005-11-08
- 28 -
(8) The second pipe 5 is fixed with the flange 33 disposed
at the second pipe 5 and the second pipe 5 is fixed to the
container 1.
[0051]
According to the present invention, the productivity
of manufacturing container can be improved. Although raw
materials of a container of this type are inexpensive, it
has many manufacturing steps such as molding, drying and
the like, therefore, the cost of manufacturing can be reduced
according to the present invention.
Furthermore, in the present invention, structure of
a storing bath having a flow path therein is explained,
however, the storing bath is not limited to this form. For
example, a storing bath with a simple cylindrical shape
may be adopted and the flow path of the molten metal can
be structured with solely a pipe made of ceramics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052]
FIG. 1 is an exploded view of the container according
to an embodiment of the present invention.
FIG. 2 is a sectional view showing the state of the
container in Fig.1 being assembled.
FIG. 3 is a plan view of FIG. 2.
FIG. 4 is a plan view (without a lid) of FIG. 2.
FIG. 5 is a plan view (with a lid) of FIG. 2.
FIG. 6 is an explanatory diagram showing a method
of producing the container (part 1).
CA 02525234 2005-11-08
- 29 -
FIG. 7 is an explanatory diagram showing a method
of producing the container (part 2).
[EXPLANATION OF CODES]
fO~531
1 Container
2 Container Body
3 Lid
4 First pipe
5 Second pipe
6 Frame
7 Inner wall
8 Insulating wall
9 Storing bath
10 Refractory and heat-insulating member
17 Protective layer
19 Hole for attaching anchor bolt
